Folding contoured wall

ABSTRACT

A contoured or modeled wall section cast in the flat in the form of a plurality of concrete panels hinged to one another and suitably arranged so that when selected panels are lifted simultaneously, other panels fold down to a predetermined position where they are secured by bolts or other devices to adjacent panels. Typically, the wall section may be formed by two parallel, spaced-apart perpendicularly-directed inner or spandrel panels. One or more minor panels may be disposed in the central aperture thus formed, hinged to the inner panels. When the inner panels are lifted, the outer and minor panels fold downwardly and are bolted in place to form a contoured wall section. The outer panel members form columns or fins, the inner panels form spandrels and the minor panels provide bracing and may function as canopies or sun shades, window sills or other modeling.

United States Patent [191 Bottjer et al.

[451 May 7,1974

[ FOLDING CONTOURED WALL [73] Assignee: Delp W. Johnson, Poole & Storm,

Architects, San Francisco, Calif.

22 Filed: Aug. 24, 1972 21 Appl. No.: 283,600

[52] US. Cl 52/70, 52/71, 52/316,

52/583, 52/745 [51] Int. Cl E04b 2/82, E04b 1/344 [58] Field of Search 52/64, 69-71,

3,494,092 2/1970 Johnson et a1 52/69 X 3,713,265 l/l973 Wysocki et al. 52/69 X 3,593,482 7/1971 Johnson....l 52/69 X Primary Examiner-Henry C. Sutherland Assistant Examiner-Leslie A. Braun 5 7] ABSTRACT A contoured or modeled wall section cast in the flat in the form of a plurality of concrete panels hinged to one another and suitably arranged so that when selected panels are lifted simultaneously, other panels fold down to a predetermined position where they are secured by bolts or other devices to adjacent panels. Typically, the wall section may be formed by two parallel, spaced-apart perpendicularly-directed inner or spandrel panels. One or more minor panels may be disposed in the central aperture thus formed, hinged to the inner panels. When the inner panels are lifted, the outer and minor panels fold downwardly and are bolted in place to form a contoured wall section. The outer panel members form columns or fins, the inner panels form spandrels and the minor panels provide bracing and may function as canopies or sun shades, window sills or other modeling.

9 Claims, 11 Drawing Figures v PATENTEDIAY 11974 v 3808l754 sum 2 UF 2 FlG 8 FOLDING CONTOURED WALL This invention relates to wall construction, and more particularly to a folding contoured wall.

In the construction of building structures such as office buildings, attempts have been made to reduce costs through the use of pre-assernbled wall sections such as pre-cast concrete wall panels Such pre-cast wall sections are generally flat and thus deficient in aesthetic appeal. The pre-casting of modeled or contoured wall sections require complex and costly molds and results in a bulky wall structure difficult to store and transport. Alternatively, contoured wall sections may be assembled from discrete pieces. However, alignment and assembly of the pieces is a difficult, time-consuming and thus costly procedure.

According to the present invention, a contoured or modeled wall section is cast in the flat in the form of a plurality of concrete panels hinged to one another and suitably arranged so that when selected panels are lifted, simultaneously other panels fold down to a predetermined position where they are secured by bolts or other devices. The lifting operation is then continued to lift the wall section to an upright position and transport same to the building structure for mounting.

Typically, the wall section may be formed by two parallel, spaced-apart outer or column panels hinged to two parallel spaced-apart perpendicularly-directed inner or spandrel panels. One or more minor panels may be disposed in the central aperture thus formed, hinged to the inner panels. When the inner panels are lifted, the outer and minor panels fold downwardly and are bolted in place to form a contoured wall section. The outer panel members thus form columns or fins, the inner panels form spandrels and the minor panels provide bracing and may function as canopies or sun shades, window sills or other modeling.

The mounting of the wall section according to the present invention may be accomplished in a variety of manners. For example, flat panels may be disposed between adjacent wall sections. Alternatively, the fins or columns of adjacent wall sections may be abutted and bolted together to form a column capable of supporting a roof system. i

Accordingly, it is an object of the present invention to provide contoured or modeled wall sections which may be formed, stored and/or transported in the flat.

Another object of the present invention is to provide contoured or modeled wall sections formed of a plurality of hingeably interconnected panels.

The folding wall construction according to the present invention is particularly advantageous in that it is formed in the flat by concrete casting employing relatively simple edge molds. When raised, a variety of aesthetically pleasing contour or modeling effects may be achieved, as for example, vertical fins and canopies. Moreover, each of the panels of the wall section may be cast with a different type or color of concrete, and each panel can be given a special texture as determined by the casting surface, to achieve an even greater variety of architectural effects.

These and other objects, features and advantages of the present invention will be more readily apparent from the following detailed description, wherein reference is made to the accompanying drawings in which:

FIG. I is a perspective view of a portion of a building incorporating wall sections'according to the present invention;

FIG. 2 is a perspective view of a stack of folding wall sections according to the present invention;

FIG. 3 is a perspective view of one of the folding wall sections depicted in FIG. 2 after the lifting and folding thereof;

FIG. 4 is a perspective view of the wall section of FIG. 3 positioned for incorporation into a building structure;

FIG. 5 is a perspective view, similar to FIG. 4, of a folding wall section according to another embodiment of the present invention;

FIG. 6 is a perspective view, similar to FIG. 2, of a stack of folding wall sections according to another embodiment of the present invention;

FIG. 7 is a perspective view, similar to FIG. 4, of one of the folding wall sections depicted in FIG. 6;

FIG. 8 is a perspective view, similar to FIG. 4, of a two-story embodiment of the folding wall section of the present invention;

FIG. 9 is a cross-sectional view of a portion of a folding wall section according to the present invention depicting the attachment of two panels;

FIG. 10 is a cross-sectional view of a portion of a folding wall section according to the present invention depictingthe waterproof hinge attachment of two panels; and

FIG. 11 is a top view illustrating the mounting of two adjacent wall sections according to the present invention.

Referring initially to FIG. 1, there is depicted a portion of a building A having three wall sections B according to the present invention. As depicted in FIG. 1, each of the wall sections B are spaced apart from one another by vertical panels C, as will be described in greater detail hereinafter. Alternatively, the wall sections B may be mounted directly adjacent one another.

Each of the wall sections B generally comprises a pair of vertically oriented columns or fin panels 10 spanned at the top and bottom by a pair of spandrel panels 12. The opening between the spandrel panels 12 defines a window 14. A sun shade or canopy is provided in the form of a minor panel 16 mounted to the upper spandrel panel 12 and the vertical panels 10.

Referring specifically to FIG. 2, the wall section B according to the present invention is formed in the flat. Specifically, edge molds may be provided on a suitable casting surface defining the various panels l0, l2 and 16. Hinges are incorporated into the mold along the hinge lines 18 between the outer panels 10 and the inner panels 12 and hinge line 20 between minor panel 16 and inner panel 12. Suitable hinge structures are disclosed in US. Pat. No. 3,494,092, issued Feb. 10, 1970, entitled INTEGRATED FOLDING SLAB CON- STRUCTION, which is incorporated herein by reference. Other hinge structures will be described in greater detail hereinafter.

Concrete or other suitable material is introduced into the edge mold. Of course, suitable reinforcing structure may be placed in the mold prior to pouring the concrete. To achieve the aesthetically pleasing effects, various grades and/or colors of concrete may be employed for the various panels 10, 12 and 16. Furthermore, the

casting surface may be suitably prepared to achieve various textures for the panels l0, l2 and 16.

Upon hardening, a layer of non-adhering material may be spread over the concrete and a second wall section B may then be cast on top of the first wall section B. As illustrated in FIG. 2, this process has been again repeated to produce a stack of three wall sections B according to the present invention. Of course, additional wall sections may be cast on the stack as thus described.

After hardening of the concrete, the wall section B is lifted, causing the panels 10 and 16 t move downwardly. Referring specifically to FIGS. 2 and 3, the wall section B is lifted by the inner panels 12 adjacent the hinge lines 18, as illustrated by the arrows in FIG. 2. Gravity urges outer panels 10 and minor panel 16 downwardly to assume the positions depicted in FIG. 3. Specifically, outer panels 10 are directed perpendicularly to inner panels 12 and minor panel 16 is angularly inclined to function as a canopy or sun shade for the window opening 14. Panels 10 and 16 are then secured in positions in a manner to be described in greater detail hereinafter, to provide a rigid wall section B. The wall section B is then righted to the position depicted in FIG. 4 prior to incorporation into the building structure.

At this point, several important observations may be made. First, it is apparent that the wall section B according to the present invention, as depicted in FIG. 4, is a free-standing, self-supporting contoured or modeled wall structure. Thus, there is no need to brace or support the wall section B during assembly of the building structure. Moreover, the wall section B according to the present invention provides a highly functional and aesthetically pleasing contoured or modeled surface. As described hereinbefore, the aesthetic effect achieved may be varied by employing different mold surfaces, and concrete textures or colors for the various panels.

Furthermore, the appearance of the wall section according to the present invention may readily be varied by simple changes of the shapes of the various panels. Referring specifically to FIG. 5, an alternative embodiment of the present invention will now be described in detail. Depicted in FIG. is a wall section D generally comprising a pair of vertical column or fin panels 22 hinged at top and bottom to a pair of spandrel panels 24. Column panels 22 and spandrel panels 24 are substantially similar to column panels and spandrel panels 12 of the previously described embodiment.

Note, however, that the shape of column panels 22 differs from the shape of column panels 10, to achieve a. different appearance from the previously described embodiment. Specifically, while column panels 10 are rectangular, the outer edge of column panels 22 is tapered, thereby achieving an architectural appearance different from the previous embodiment. It is thus apparent that the configuration of the outer or column panels may readily be varied to alter the appearance of the wall section according to the present invention.

A minor panel 26, similar to minor panel 16 of the previous embodiment, is hinged'to the upper spandrel panel 24. In accordance with this embodiment, a second minor panel 28, hingedly mounted to the lower spandrel panel 24, is also provided. As is apparent from FIG. 5, minor panels 26 and 28 cooperate to define an inclined window opening 30, minor panel 28 functioning as a window sill or ledge. The inclined mounting of window 30, thus described, produces an aesthetically pleasing architectural effect and is additionally advantageous in that the inclined mounting on the window 30 tends to minimize the accumulation of dirt on the outside surface thereof.

It is thus apparent that the folding wall section construction according to the present invention possesses great flexibility in shape and appearance. This will be even more apparent from a consideration of other embodiments of the present invention. Referring specifically to FIGS. 6 and 7, another embodiment of the present invention will now be described in detail. Specifically, there is depicted a wall section B generally comprising a pair of vertical column panels 32 spanned at the top and bottom by a pair of spandrel panels 34. A minor panel 36 is hingeably mounted to upper spandrel panel 34. Column panels 32, spandrel panels 34 and minor panel 36 generally correspond to column panels 10, spandrel panels 12 and minor panels 16, the first described embodiment of the present invention. I It may be observed, however, that in accordance with the previously described embodiments, the column panels, upon folding, are generally perpendicular to the spandrel panels. In accordance with the embodiment depicted in' FIGS. 6 and 7, column panels 32 are not perpendicular to spandrel panels 34, but rather taper outwardly to produce a pleasing variation in architectural appearance. To this end, the mold lines 38 between the sides of minor panel 36 and column panels 32, are angled, as depicted in FIG. 6. Thus, the resultant minor panel 36 will be trapezoidal rather than rectangular as previously described. Upon folding, column panels 32 will abut the edge of minor panel 36 in the outwardly tapering configuration depicted in FIG. 7. By securing column panels 32 to minor panel 36, the desired configuration will thus be achieved.

It is thus apparent that the configuration of the minor panel determines the angular relationship between the column and spandrel panels, upon folding. In this manner, further variation may be achieved in the architectural appearance of the folding wall section according to the present invention. For example, the minor panel may be cast in an inwardly tapering trapezoidal configuration, rather than the outwardly tapering trapezoidal configuration depicted in FIGS. 6 and 7. When folded, the column panels will thus taper inwardly in abutment with the minor panel.

In accordance with the previously described embodiments of the present invention, a single story wall section is provided. Alternatively, the wall section according to the present invention may be embodied as a mu]- ti-storied structure. Referring to FIG. 8, a two-story wall section according to the present invention will now be described in detail. Specifically, there is depicted a two-story wall section F generally comprising a pair of vertical panels 40 hinged to three spandrel panels 42. Two minor panels 44 are hinged to the upper and central spandrel panels 42, and function as canopies or sun'shades as well as bracing for the vertical panels 40. As is apparent from FIG. 8, column panels 40, spandrel panels 42 and minor panels 44 correspond to column panels 10, spandrel panels 12 and minor panel 16 of the first described embodiment. It is noteworthy, however, that the length of the column panels 40 substantially exceeds the length of column panels 10. Moreover,

three spandrel panels 42 are employed, rather than two spandrel panels 12.

Accordingly, the height of the wall section according to the present invention may be simply increased by lengthening the column panels and providing additional spandrel panels therebetween. While a two-story wall section has been depicted in FIG. 8, it is apparent that even taller multi-storied wall sections may be constructed in a similar fashion.

FIG. 8 further illustrates the variety of architectural effectsafforded by slight variations in the shapes of the panels. Specifically, the corners 40a of column panels 40 are depicted as being bevelled to provide a different appearance than the rectangular columns 10.

Referring now to FIGS. 9 through 11, various con struction details of the wall section according to the present invention will now be described in detail. For this purpose, reference is made to the first described embodiment of the present invention. Of course, the construction details to be described are equally applicable to all of the described embodiments.

Referring specifically to FIG. 9, the attachment of the outer panels to the minor panels will now be described in detail. As previously described, column panel 10 abuts minor panel 16 upon folding. Thus, rigid attachment therebetween may be accomplished by merely providing a bolt 50 extending through column panel 10 into minor panel 16. To minimize the visibility of bolt 50, the head thereof may be recessed into column panel 10, as depicted in FIG. 7. Of course, both of the column panels 10 are attached to minor panel 16, as thus described, to brace and thus make rigid the wall section according to the present invention.

Referring now to FIG. 10, a waterproof hinge structure particularly suitable for mounting the minor panels to the spandrel panels will now be described in detail. Specifically, it is desirable to make the hinge joint between the minor panel and spandrel panel waterproof, to prevent rain from impinging directly upon the window. To this end, a hinge structure may be provided in the form of an elongate flexible strip joining the spandrel and minor panels. Referring to FIG. 10, an elongate flexible strip 60 spanning spandrel l2 and minor panel 16 and cast therein is provided. As is apparent from FIG. 10, strip 60 is preferably of curved cross section, to facilitate the bending thereof upon the folding and erection of the wall section. Strip 60 may be metal, plastic or other suitable flexible material.

In order to define the desired angular relationship between spandrel panel 12 and minor panel 16, the abutting edges 12a and 16a of spandrel panel 12 and minor panel 16 are bevelled. Thus, upon the lifting of spandrel panel 12, the weight of minor panel 16 will cause elongate metal strip 60 to bend in the desired hingelike manner. Edges 12a and 16a will then abut, as depicted in FIG. 10, to define the exact desired angular position of the minor panel 16 with respect to the spandrel panel 12. By employing such a continuous hinge strip, a substantially waterproof hinge joint is thus formed.

Referring now to FIG. 11, the hinge mounting of the column panels to the spandrel panels will now be described in detail. Specifically, column panels 10 may simply be hinged to column panel 12 by a plurality of metal hinges 70 cast therein. While such construction does not provide a waterproof joint therebetween, the

joint may later be'waterproofed by grouting or the like after adjacent wall sections are assembled.

Assembly of adjacent wall sections is also depicted in FIG. 11. Specifically, a flat concrete panel C may be provided between adjacent wall sections B according to the present invention. Panel C includes, of course, suitable slots for the receipt of hinges 70. The abutting edges of wall sections B and panel C may be grouted or otherwise filled to waterproof the building structure in accordance with the present invention. It may be observed that such construction substantially conceals all hinge structures. Thus, the resultant building structure does not reveal unsightly hinges, but instead presentsinvention may be mounted in a variety of alternative manners. For example, wall sections may be mounted directly adjacent one another. Alternatively, other conventional mountings for structural or curtain walls may be employed.

Accordingly, wall construction in accordance with the present invention provides a contoured or modeled wall section or module which may be formed, stored and/or transported in the flat. Substantial savings in costs and labor may thus be achieved. The wall section according to the present invention may be either of the structural or curtain variety. It is apparent from the various described embodiments that great variation may be achieved in architectural effect by suitable variation in the shape of the various panels.

While particular embodiments of the present invention have been shown and described in detail, it is apparent that other adaptations and modifications will occur to those skilled in the art, which adaptations and modifications are specifically within the scope of the present invention, as set forth in the claims.

What is claimed is:

l. A wall section comprising: a plurality of rigid panels including a pair of spaced-apart outer panels having parallel inner edges, a pair of spaced-apart inner panels having parallel outer edges, and a minor panel; means hingeably connecting parallel outer edges of said inner panels to parallel inner edges of said outer panels, said means allowing gravity to pivot said outer panels down wardly from horizontal positions coplanar to said inner panels; second means hingeably connecting an edge of said minor panel to a parallel edge of an inner panel on a line perpendicular to the parallel outer edges of the inner panel, said second means allowing gravity to pivot said minor panel downwardly from a position coplanar to said inner and outer panels; and means for securing said minor panel to said outer panels after said panels occupy their downwardly pivotted positions.

2. The wall section of claim 1, said minor and outer panels having rectilinear edges which are adjacent and essentially parallel when said panels are positioned in coplanar relation.

3. The wall section of claim 2, said rectilinear edges of said outer panels being inclined relative to the parallel inner edges thereof.

4. A wall section precast in the flat comprising a pair of parallel spaced-apart outer panels, at least two spaced-apart inner panels disposed in the flat between said outer panels, at least one minor panel disposed in the flat between said inner panels adjacent one of said inner panels, hinge means hingedly interconnecting said outer panels and said inner panels and said minor panel and said one inner panel and attachment means for connecting said outer panels and said minor panel when said hinge means is folded, said attachment means comprising a plurality of bolts interconnecting said outer and minor panels when said hinge means is folded to abut said outer and minor panels.

5. A method of constructing a contoured wall section with a plurality of rigid panels, comprising the steps: forming a plurality of panels in a common horizontal plane including a first pair of spaced-apart panels having parallel inner edges, a second pair of spaced-apart panels located between said first pair of panels and having edges parallel and adjacent to the inner edges of said first pair of panels, and a minor panel located within the confines of said first and second pairs of panels; hingeably connecting the parallel and adjacent edges of said first and second pairs of panels to allow pivotal downward movement of said first pair of panels relative to said edges; hingeably connecting said minor panel to one of said second pair of panels on a line perpendicular to said paralleland adjacent edges; lifting said panels while allowing said first pair of panels and minor panel to gravitate downward relative to their hinged edges until edges of said minor panel contact surfaces of said first pair of panels; then securing said minor panel to said first pair of panels to immobilize said panels and form a contoured wall section.

6. A method of constructing a contoured wall section comprising the steps of forming in a plane a pair of spaced-apart outer panels hingeably connected to at least two spaced-apart inner panels disposed between said outer panels and at least one minor panel hingeably connected to one of said. inner panels, said step comprising providing an edge mold defining said panels, inserting hinges into said edge mold between said panels and pouring concrete into said edge mold; folding said outer panels and said minor panel into abutting relationship; and attaching said outer panels and said minor panel.

7. The method according to claim 6 wherein the step of folding comprises lifting said inner panels so that gravity urges said outer and minor panels to pivot downwardly.

8. The method according to claim 7 wherein the downward pivotal movement of said minor panel is limited to incline said minor panel at an angle less than perpendicular to said inner panel.

9. The method according to claim 7 wherein the step of attaching comprises bolting said outer panels to said minor panel. 

1. A wall section comprising: a plurality of rigid panels including a pair of spaced-apart outer panels having parallel inner edges, a pair of spaced-apart inner panels having parallel outer edges, and a minor panel; means hingeably connecting parallel outer edges of said inner panels to parallel inner edges of said outer panels, said means allowing gravity to pivot said outer panels downwardly from horizontal positions coplanar to said inner panels; second means hingeably connecting an edge of said minor panel to a parallel edge of an inner panel on a line perpendicular to the parallel outer edges of the inner panel, said second means allowing gravity to pivot said minor panel downwardly from a position coplanar to said inner and outer panels; and means for securing said minor panel to said outer panels after said panels occupy their downwardly pivotted positions.
 2. The wall section of claim 1, said minor and outer panels having rectilinear edges which are adjacent and essentially parallel when said panels are positioned in coplanar relation.
 3. The wall section of claim 2, said rectilinear edges of said outer panels being inclined relative to the parallel inner edges thereof.
 4. A wall section precast in the flat comprising a pair of parallel spaced-apart outer panels, at least two spaced-apart inner panels disposed in the flat between said outer panels, at least one minor panel disposed in the flat between said inner panels adjacent one of said inner panels, hinge means hingedly interconnecting said outer panels and said inner panels and said minor panel and said one inner panel and attachment means for connecting said outer panels and said minor panel when said hinge means is folded, said attachment means comprising a plurality of bolts interconnecting said outer and minor panels when said hinge means is folded to abut said outer and minor panels.
 5. A method of constructing a contoured wall section with a plurality of rigid panels, comprising the steps: forming a plurality of panels in a common horizontal plane including a first pair of spaced-apart panels having parallel inner edges, a second pair of spaced-apart panels located between said first pair of panels and having edges parallel and adjacent to the inner edges of said first pair of panels, and a minor panel located within the confines of said first and second pairs of panels; hingeably connecting the parallel and adjacent edges of said first and second pairs of panels to allow pivotal downward movement of said first pair of panels relative to said edges; hingeably connecting said minor panel to one of said second pair of panels on a line perpendicular to said parallel and adjacent edges; lifting said panels while allowing said first pair of panels and minor panel to gravitate downward relative to their hinged edges until edges of said minor panel contact surfaces of said first pair of panels; then securing said minor panel to said first pair of panels to immobilize said panels and form a contoured wall section.
 6. A method of constructing a contoured wall section comprising the steps of forming in a plane a pair of spaced-apart outer panels hingeably connected to at least two spaced-apart inner panels disposed between said outer panels and at least one minor panel hingeably connected to one of said inner panels, said step comprising providing an edge mold defining said panels, inserting hinges into said edge mold between said panels and pouring concrete into said edge mold; folding said outer panels and said minor panel into abutting relationship; and attaching said outer panels and said minor panel.
 7. The method according to claim 6 wherein the step of folding comprises lifting said inner panels so that gravity urges said outer and minor panels to pivot downwardly.
 8. The method according to claim 7 wherein the downward pivotal movement of said minor panel is limited to incline said minor panel at an angle less than perpendicular to said inner panel.
 9. The method according to claim 7 wherein the step of attaching comprises bolting said outer panels to said minor panel. 